随机声载荷作用下的复杂薄壁结构Von Mises应力概率分布研究

随机声载荷作用下的某些复杂薄壁结构的振动疲劳属于多轴疲劳,Von Mises 应力准则是多轴疲劳损伤分析的一条有效途径。本文通过对有限带宽高斯白噪声载荷作用下结构Von Mises应力概率分布研究,分析提出Von Mises应力服从双参数Weibull分布或Lognormal分布,并且给出了估算这两种概率分布参数的方法,进而得到了Von Mises应力峰值概率密度函数,从而为结构的疲劳损伤寿命估算提供依据。在工程应用中采用耦合的有限元和边界元方法计算了某型航空发动机燃烧室火焰筒薄壁结构在随机声载荷作用下的振动应力响应功率谱密度,着重分析了Von Mises应力响应的概率分布特征,并对分析结果采用Kolmogorov-Smirnov (K-S)检验进行了比较验证。     

概率局部应力应变法

实际工程中的结构件往往具有多个不确定因素,包括材料、几何、载荷等。这些不确定因素导致构件的局部应力应变响应和疲劳寿命响应具有随机性。因此对低周疲劳分析中的局部应力应变法进行了概率分析。通过基本随机变量将诺伯法中的循环应力应变曲线(迟滞回线)和诺伯公式表示为概率曲线,基本随机变量反映了构件的不确定因素。通过建立近似拟合多项式的方法,求得局部应力应变的随机响应。将应变寿命曲线视为概率曲线,采用随机累积损伤理论,通过同样方法得到疲劳寿命的随机响应。算例表明结果与蒙特卡罗模拟的结果十分接近。该方法是一个简单有效的疲劳寿命概率分析方法。     

不同超弹性本构模型和多维应力下开裂能密度的计算方法

橡胶隔振器的疲劳失效多属于大变形(有限变形)下的多轴疲劳问题。在多轴疲劳载荷下,有效用来驱动裂纹扩展的那部分应变能密度称为开裂能密度。基于开裂能密度和橡胶材料的裂纹扩展特性预测橡胶部件的疲劳寿命时,须计算在外载荷下橡胶部件的开裂能密度。为了由有限元软件ABAQUS默认输出的应变计算在有限变形下的开裂能密度,该文推导了不同超弹性本构模型下开裂能密度在主坐标系下的计算式和所需的积分方法。基于该文开裂能密度的计算方法,采用3次Ogden本构来描述大变形下橡胶材料的本构行为,计算分析了不同应变状态下开裂能密度的分布特点。通过分析计算得到的开裂能密度与应变能密度的关系,说明该文开裂能密度计算方法的准确性。最后将上述计算方法应用到橡胶隔振器的多轴疲劳寿命预测中。     

液压模块挂车刚柔耦合动态响应特性及摆臂疲劳分析

为了研究重型液压模块挂车动态响应特性及其摆臂疲劳强度的问题,基于有限元分析方法与刚柔多体动力学理论,建立挂车刚柔耦合多体动力学模型,以路面不平度作为仿真的激励信号,结合振动试验验证模型的准确性。对挂车在不同的运行工况下,进行动态响应仿真分析。将多体动力学仿真结果作为有限元分析的动载荷,计算获得疲劳分析所需要的应力时间历程,运用局部应力应变法对摆臂进行疲劳寿命预测。计算结果表明,摆臂应力集中部位出现在已发生断裂的断面位置及应力水平已进入塑性状态。挂车在B级、C级与D级路面下的运行,危险点的疲劳寿命均大于挂车使用年限。而在正弦形凹凸路面冲击下,危险点的疲劳寿命随正弦形幅值与车速增加而明显减短。根据仿真计算结果,可提出适用的运行工况以提高挂车运行安全性与运输效率。     

一种新的铝合金应变疲劳计算方法

提出了一种在铝合金构件应变疲劳分析中,计算局部应力和应变变程的新方法。这种方法称作应力功恒等法。采用这种新方法,计算了2024-T42铝合金试件在恒幅循环载荷作用下的疲劳寿命,并将疲劳寿命计算结果与试验结果进行了对比分析。对比分析结果表明,采用这种新方法计算构件应力集中处的局部应力和应变变程,具有较高的计算精度。     

油管螺纹应力应变场的有限元分析与检测

利用ANSYS大型分析软件,建立了属于表面非线性和材料非线性相偶合问题的油管接头的弹塑性轴对称接触有限元模型,对油管接头在不同载荷工况和不同配合下的应力应变场进行了数值计算。又用电测法对油管接头的油管内壁进行了实际测量。对比两种不同方法得到的结果,验证了轴对称模型有限元法的适用范围。可靠地给出了工程中最危险截面应力应变场的各种变化规律,为研究油管的疲劳断裂问题提供了重要的理论分析依据和数据。     

随机复杂应力场塑性应变能的疲劳寿命分析

本文通过分析疲劳破坏的本质,并借鉴目前应变能理论的最新成果,提出了一种随机复杂应力场下基于塑性应变能的疲劳寿命分析模型,以此来预测材料的多轴低周疲劳寿命.模型中的相关材料参数通过MATLAB拟合单轴及纯剪切疲劳试验数据得到,使用有限元软件ANSYS模拟试件的多轴加载情况,并从其后处理程序中提取模型中需要的数据.通过对光滑试件SM45C,304和缺口件GH4169,16MnR的计算验证,其结果表明该模型对多轴随机应变加载低周疲劳寿命具有很好的预测效果.     

应用局部应力-应变法计算联轴器膜片疲劳寿命

由于轴线间的角向不对中,联轴器旋转时膜片中产生交变应力,引起疲劳问题。使用中需要考虑其疲劳寿命。本文对六孔圆环形和束腰形膜片,利用有限元方法和薄板弯曲理论建立膜片应力计算模型。引入改进的局部应力－应变法,建立计算膜片联轴器膜片疲劳裂纹形成寿命的模型和方法。定量分析两种形式膜片的应力、附加载荷和疲劳寿命,最后,得出对膜片组设计有参考价值的结论。结论表明,对于设计合理的膜片,其疲劳寿命能满足机组工作要求。     

热交变载荷下10%Cr耐热钢蠕变疲劳裂纹萌生特征

为调节新能源间歇式发电模式所带来的弊端,需要使用火力发电厂调峰稳定电网波动。调峰过程中机组频繁启停,加剧高温部件的疲劳蠕变损伤。通过分析现有寿命模型描述温度交变载荷下汽轮机转子钢性能的不足,提出预载荷实验方案。且以预载荷实验数据为基础,优化现有寿命预测模型。通过模拟交变温度下的临近工况实验,对比应力应变关系和疲劳蠕变寿命,对所优化的寿命模型进行了评估。     

基于应力概率密度和功率谱密度法的随机声疲劳寿命预估方法研究

针对航空发动机燃烧室火焰筒结构的声疲劳问题,研究了一种用于随机载荷下结构疲劳寿命预估的有效方法。首先,对薄壁结构在随机载荷作用下的Von Mises应力过程的概率分布作了研究,给出了应力峰值概率密度函数的表达式。基于Miner线性理论,提出了基于应力概率密度和功率谱密度法的随机声疲劳寿命预估方法,并建立了疲劳寿命预估模型。以某型航空发动机燃烧室火焰筒结构为例,在采用耦合的有限元和边界元方法计算出随机声疲劳应力基础上,应用所建立的模型进行了疲劳寿命估算,并对计算结果进行了宽带修正。结果表明,该方法对航空薄壁结构随机疲劳寿命分析具有实用性。     

Prediction of multiaxial fatigue life for complex three‐dimensional stress state considering effect of additional hardening

In engineering practice, it is generally accepted that most of components are subjected to multiaxial stress‐strain state. To analyse this complicated loading state, different types of specimens of 2A12 (2124 in the United States) aluminium alloy were tested under multiaxial loading conditions and a new multiaxial fatigue analysis method for the state of three‐dimensional stress and strain is proposed. Elastic‐plastic finite element method (FEM) and a proposed vector computing method are used to describe the loading state at the critical point of specimen, by which the parameter Γ_T is calculated at the new defined subcritical plane to consider the effect of additional cyclic hardening. Meanwhile, the principal equivalent strain is still calculated at the traditional critical plane. The new damage parameter is composed of different process parameters, by which the dynamic path of strain state, including loading environments and material properties, are fully considered in one loading cycle. According to experimental verifications with 2A12 aluminium alloy, the results show that the proposed method shows satisfactory, accurate, and reliable results for multiaxial fatigue life prediction in the state of three‐dimensional stress and strain.     

Calculation of elasto-plastic strains and stresses in notches under multiaxial loading

A method for calculating elasto-plastic notch tip strains and stresses in bodies subjected to multiaxial loading has been presented. The method has been formulated in terms of strain energy density relationships. Two approximate formulae are derived based on the analysis of strain energy density in the notch tip region. The two formulae represent the lower and upper limits of the band within which the actual elasto-plastic notch tip strains can be found. All necessary relationships are derived for a general multiaxial stress state. The calculated notch tip strain and stress components are compared with experimental and finite element data obtained for a variety of loading conditions and materials. This method may be particularly useful for stress/strain analysis of notched components subjected to lengthy multiaxial cyclic loading histories.On leave from Warsaw University of Technology.     

Notch fatigue life prediction considering nonproportionality of local loading path under multiaxial cyclic loading

An innovative numerical methodology is presented for fatigue lifetime estimation of notched bodies experiencing multiaxial cyclic loadings. In the presented methodology, an evaluation approach of the local nonproportionality factor F for notched specimens, which defines F as the ratio of the pseudoshear strain range at 45° to the maximum shear plane and the maximum shear strain range, is proposed and discussed deeply. The proposed evaluation method is incorporated into the material cyclic stress‐strain equation for purpose of describing the nonproportional hardening behavior for some material. The comparison between multiaxial elastic‐plastic finite element analysis (FEA) and experimentally measured strains for S460N steel notched specimens shows that the proposed nonproportionality factor estimation method is effective. Subsequently, the notch stresses and strains calculated utilizing multiaxial elastic‐plastic FEA are used as input data to the critical plane‐based fatigue life prediction methodology. The prediction results are satisfactory for the 7050‐T7451 aluminum alloy and GH4169 superalloy notched specimens under multiaxial cyclic loading.     

Elastic-plastic analysis of a stationary crack under cyclic loading and effect of overload

A recently proposed elastoplastic constitutive model has been implemented in a finite element code to study crack front behaviour under variable loading. The importance of proper modelling of a material's behaviour becomes evident when a variable loading condition is considered. We present stress, strain and displacement distribution along a stationary crack front for constant amplitude cyclic loading with an overload cycle. The analysis predicts a decreased tensile stress and damage accumulation following an overload.     

Werkstoffmechanische Beanspruchungsanalyse gekerbter Strukturen bei synchronen Belastungskombinationen

Elastic‐Plastic analysis of notched structures under synchronous cyclic loading This paper focuses on analysing the elastic‐plastic stress‐strain behaviour at the failure‐critical location of notched components and structures under multiaxial synchronous cyclic loading. For this, various load configurations are investigated numerically consisting of constant and cyclic load components with constant and variable amplitudes. The von Mises yield criterion and the kinematic hardening rule of Prager and Ziegler describe the elastic‐plastic material property. The finite element software of ABAQUS is used to solve the boundary element problem. A parametrical study is carried out and numerical results are presented to show the effects of load amplitude, mean load and spectrum shape on the local stress‐strain paths.     

Fatigue life prediction method of face-centered cubic single-crystal metals under multiaxial nonproportional loading based on structural mechanical model

Based on the characteristics of the sliding surface, sliding direction, and fatigue damage mechanism of metal materials, the mechanical model of a body–bar–plate structure is proposed with consideration to the plastic damage mechanism. The elastoplastic constitutive equations and damage constitutive equations of the face-centered cubic (FCC) structure subjected to multiaxial cyclic loading were derived, and the damage evolution law of the body–bar–plate mechanical model was investigated. Then, the meso-damage evolution equation was established under multiaxial nonproportional loading. Subsequently, the relationship between the fatigue performance and microstructure under multiaxial nonproportional loading was investigated, and a damage mechanics–finite element method (FEM) with consideration to the damage evolution is proposed. The proposed model and method provide a new approach for predicting the fatigue life of metal materials.     

A notch strain calculation of a notched specimen under axial-torsion loadings

In this paper, a notch analysis model is presented for the numerical prediction of multiaxial strains of a notched 1070 steel specimen under combined axial and torsion loadings. The proposed model is based on the notion of a structural yield surface and uses a small-strain cyclic plasticity model to describe stress–strain relations. A notch load–strain curve is calculated with Neuber’s rule and incremental nonlinear finite element analysis. The presented model is applied to simulate the notch root deformations of a circumferentially notched specimen under cyclic tension–compression–torsion loading histories. The model predictions are evaluated with strain measurements at the notch root of the specimen in a comprehensive set of cyclic tests. The computed strain loops were in accord with experimental data and matched qualitatively with measured shear–axial strain histories irrespective of loading path of the test. In proportional balanced torsion-axial loading, the nonlinear shear strain–axial strain loops were calculated properly. The modeling errors were determined to be a function of the loading path shape, and compared to shear strains, axial strain predictions were more accurate.     

Multiaxial notch fatigue life prediction based on pseudo stress correction and finite element analysis under variable amplitude loading

A new computational methodology is proposed for fatigue life prediction of notched components subjected to variable amplitude multiaxial loading. In the proposed methodology, an estimation method of non‐proportionality factor (F) proposed by authors in the case of constant amplitude multiaxial loading is extended and applied to variable amplitude multiaxial loading by using Wang‐Brown's reversal counting approach. The pseudo stress correction method integrated with linear elastic finite element analysis is utilized to calculate the local elastic‐plastic stress and strain responses at the notch root. For whole local strain history, the plane with weight‐averaged maximum shear strain range is defined as the critical plane in this study. Based on the defined critical plane, a multiaxial fatigue damage model combined with Miner's linear cumulative damage law is used to predict fatigue life. The experimentally obtained fatigue data for 7050‐T7451 aluminium alloy notched shaft specimens under constant and variable amplitude multiaxial loadings are used to verify the proposed methodology and equivalent strain‐based methodology. The results show that the proposed methodology is superior to equivalent strain‐based methodology.     

Multiaxial fatigue life prediction method in the ground vehicle industry

The extensive progress which has been made in the multiaxial fatigue area over the past 5 to 10 years has allowed wider application of the multiaxial fatigue method in component durability design in the ground vehicle industry. The method adopts the long established local strain–life approach and includes several new features. (1) A three-dimensional cyclic stress–strain model, used to simulate the elastic–plastic material behavior under complicated loadings. (2) The critical plane approach, which requires the fatigue analysis to be performed on various potential failure planes before determining the lowest fatigue life. (3) A biaxial damage criterion, to better quantify fatigue damage under various loading conditions. (4) A multiaxial Neuber equivalencing technique, used to estimate, from the elastic finite element stress results, the multiaxial stress and strain history of plastically deformed notch areas. This paper examines the application of the above features to the fatigue analyses of three generic service/test histories: a constant amplitude (baseline) test history, a history directly recorded by strain gages mounted on the critical location of a structural component, and a loading history recorded in multichannels for a complex structure.     

Simulation of cyclic stress/strain evolutions for multiaxial fatigue life prediction

This study deals with simulation for cyclic stress/strain evolutions and redistributions, and evaluation of fatigue parameters suitable for estimating fatigue lives under multiaxial loadings. The local cyclic elastic–plastic stress–strain responses were analyzed using the incremental plasticity procedures of ABAQUS finite element code for both smooth and notched specimens made of three materials: a medium carbon steel in the normalized condition, an alloy steel quenched and tempered and a stainless steel, respectively. Emphasis is on the studying of ‘intelligent’ material behaviors to resist fracture, such as stress redistribution and relaxation through plastic deformations, etc. For experimental verifications, a series of tests of biaxial low cycle fatigue composed of tension/compression with static and cyclic torsion were carried out on a biaxial servo-hydraulic testing machine (Instron 8800). Different multiaxial loading paths were used to verify their effects on the additional cyclic hardening. The comparisons between numerical simulations and experimental observations show that the FEM simulations allow better understanding on the evolutions of the local cyclic stress–strain and it is shown that strong interactions exist between the most stressed material element and its neighboring material elements in the plastic deformations and stress redistributions. Based on the local cyclic elastic–plastic stress–strain responses, the energy-based multiaxial fatigue damage parameters are applied to correlating the experimentally obtained lives. Improved correlations between the predicted and the experimental results are shown. It is concluded that the improvement of fatigue life prediction depends not only on the fatigue damage models, but also on the accurate evaluations of the cyclic elasto-plastic stress/strain responses.